Utv portal axle system

ABSTRACT

A UTV portal axle system is disclosed, including a spindle with a housing for housing input and output drive gears coupled by one or more idler gears. The output drive gear is disposed lower than the input drive gear to provide additional ground clearance to the UTV. The king pin axis angle is substantially the same as that of a stock UTV, while maintaining a scrub radius of substantially one inch or less. This is accomplished by the lower control arm ball joint being located within a recess of the output drive gear. This allows the UTV to be properly controlled when driven at high speeds over rough or uneven terrain. The gears may be interchangeable to allow the gear ratio to be adjusted to be more suitable for use at various driving speeds. A method of changing the gear ratio is also disclosed.

CROSS REFERENCE TO RELATED APPLICATION[S]

This application claims priority to U.S. Provisional Patent Applicationto Justin Smith entitled: “UTV PORTAL AXLE SYSTEM,” Ser. No. 62/756,349,filed Nov. 6, 2018, the disclosure of which is hereby incorporatedentirely herein by reference.

BACKGROUND OF THE INVENTION Technical Field

This invention relates generally to portal axle systems for vehicles andparticularly to a portal axle system with correct geometry and multiplegear sets for use on a utility task vehicle in both low-speed andhigh-speed applications.

State of the Art

Conventional portal axles are often used on off-road vehicles to provideincreased ground clearance of differential housings and to allow forgear ratios that reduce the torque required in axle shafts to deliverthe same power to the wheels by using higher shaft rotational velocity.

Typically, a conventional portal axle system for a utility task vehicle(UTV) is sold as an after-market system. Stock axle, spindle and wheelsystems of UTVs have a scrub radius that is substantially one (1) inchor less, wherein the scrub radius is the distance in front view betweenthe king pin axis and the center of the contact patch of the tire, whereboth would theoretically touch the road, and the kingpin axis is theline passing through the centers of the upper and lower ball joints ofthe spindle. UTVs having a scrub radius of substantially one (1) inch orless provide a comfortable amount of feedback to a driver, through thesteering wheel of the UTV, while the UTV is in motion, and particularlywhen executing turns, at low speeds and high speeds.

One problem with conventional after-market UTV portal axle systems isthat, in order to maintain the correct kingpin axis inclination angle,as in a stock system, the scrub radius is necessarily increased, due tothe size and shape of the spindle of such conventional systems. Forexample, the scrub radius may be increased, from substantially one inchor less, in stock systems, to two or three inches after the conventionalportal axle system is installed. Although it is not ideal, a large scrubradius may be acceptable for conventional systems with intended use onUTVs for low-speed applications, such as rock crawling and mud boggingat speeds of less than about thirty (30) mph, for example. However, sucha large scrub radius creates significant problems for UTVs used inhigh-speed applications at more than about thirty (30) mph, such asracing. For example, at high speeds, the large scrub radius ofconventional systems causes a significantly large amount of feedback tothe vehicle driver, through the steering wheel of the vehicle, makingthe vehicle very difficult for the driver to rotate the steering wheelfor turning at high speeds. In addition, at high speeds over rough anduneven terrain, significant shock loads are transferred from the wheelsto the steering wheel, causing jolting in the steering wheel andpossibly ripping the steering wheel from the driver's hands. Inaddition, shock loads are similarly transferred from the wheels to otherfront-end parts and steering racks, causing damage to these and othervehicle components. Furthermore, the uncontrollability of the UTV athigh speeds, due to the large scrub radius, poses a risk of the drivercrashing the vehicle.

A second problem with conventional portal axle systems is that they havea single gear ratio that is often intended for use on UTVs for low-speedapplications, such as rock crawling and mud bogging at speeds of lessthan about thirty (30) mph, for example. The single low-speed gear ratiois advantageous in that it reduces the torque required in axle shafts todeliver the same power to the wheels, as in stock systems, by usinghigher shaft rotational velocity. However, the single low-speed gearratio of conventional after-market portal axle systems is not suitablefor use on UTVs at high speeds of about thirty (30) mph or more.

Accordingly, an improved portal axle system is needed for use on UTVs inboth low and high-speed applications.

SUMMARY OF THE INVENTION

The present invention relates generally to portal axle systems forvehicles and particularly to a portal axle system with correct geometryand multiple interchangeable gear sets for use on a UTV in bothlow-speed and high-speed applications.

Embodiments of a UTV portal axle system comprise a spindle having anintegrated housing for housing a set of gears. The spindle has an upperbracket configured for coupling to an upper control arm of a UTV and alower bracket configured for coupling to a lower control arm of the UTV.

Embodiments comprise an input drive gear and an output drive gear housedwithin the housing. Some embodiments also comprise at least one idlergear housed within the housing. The input drive gear may be rotationallycoupled within the housing and configured for coupling to a drive axleof the UTV. The output drive gear may also be rotationally coupledwithin the housing and configured for coupling to a wheel hub shaft ofthe UTV. The output drive gear may be disposed a predetermined spaceddistance below, and substantially coplanar with, the input drive gear,such that the output drive gear does not engage the input drive gear.The distance between the centers of the input and output drive gearscorresponds to the amount of additional lift, or ground clearance,provided to the UTV by the UTV portal axle system.

Torque may be transferred from the input drive gear to the output drivegear by means of at least one idler gear rotationally coupled within thehousing, wherein the at least one idler gear is disposed substantiallycoplanar with the input and output drive gears.

The output drive gear is a recessed gear. The recess of the output drivegear allows for the lower bracket to be disposed within the recess,thereby maintaining the scrub radius to not more than one inch while theoriginal stock king pin axis inclination angle is maintained. In thisway, the geometry of the original stock suspension system issubstantially maintained, allowing for safe use of the UTV on roughterrain and/or at high speeds, such as at speeds over 30 mph, withoutthe steering feedback problems associated with conventional after-marketUTV portal axle systems.

In some embodiments, any of the input drive gear, the output drive gear,and the at least one idler gear, may be removable and replaceable with agear of a different diameter. Thus, the gear ratio between input to andoutput from the gear box may be increased or decreased. A lower gearratio may be suitable for use of the UTV at low speeds, and a highergear ratio may be suitable for use of the UTV at high speeds.

A method of changing the gear ratio of a UTV portal axle system is alsodisclosed.

The foregoing and other features and advantages of the present inventionwill be apparent from the following more detailed description of theparticular embodiments of the invention, as illustrated in theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconnection with the Figures, wherein like reference numbers refer tosimilar items throughout the Figures, and:

FIG. 1 is a front section view of a UTV portal axle system in accordancewith an embodiment;

FIG. 2 is another front section view of a UTV portal axle system inaccordance with an embodiment;

FIG. 3 is a side section view of a UTV portal axle system in accordancewith an embodiment;

FIG. 4 is a perspective view of a UTV portal axle system in accordancewith an embodiment; and

FIG. 5 is a block diagram showing steps of a method of use of a UTVportal axle system in accordance with an embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As discussed above, embodiments of the present invention relategenerally to portal axle systems for vehicles and particularly to aportal axle with correct geometry and multiple gear sets for use on autility task vehicle (UTV) in both low-speed and high-speedapplications.

A UTV, for purposes of this application, includes any of a class ofvehicles to which any of the following names, without limitation, hasbeen attributed: Utility Task Vehicle (UTV), Utility Terrain Vehicle(UTV), Recreational Off-Highway Vehicle (ROV), Recreational UtilityVehicle (RUV), and Side-by-Side (SXS). Most conventional UTVs in usetoday share the following characteristics, without limitation: off-roaddesign, at least four wheels, at least one non-straddle seat with abelt, a steering wheel, foot pedals, a roll cage, a width of less than65 inches, and an unladen dry weight of less than 2,000 lbs. Althoughthese characteristics are not intended to be limiting, it should beunderstood that conventional UTVs are distinguishable from conventionalATVs having a straddle seat and handle bar steering, such as fourwheelers, quads, or the like, as well as from other general-purposepassenger vehicles used in off-roading, such as Jeeps, Hummers, pickuptrucks, and the like.

Referring to the drawings, as shown in FIGS. 1-4, embodiments of a UTVportal axle system 10 comprise a spindle 12 having an integrated housing14 for housing a set of gears 16. As with conventional spindles, thespindle 12 has an upper bracket 20 configured for operational couplingto an upper control arm 22 of a UTV and a lower bracket 24 configuredfor operational coupling to a lower control arm 26 of the UTV. Each ofthe upper and lower control arms 22 and 26 may be coupled to the upperand lower brackets 20 and 24, respectively, using a coupling device 28such as a ball joint, for example. The spindle 12 may also have abracket 30 for coupling to a steering mechanism tie rod 32 of the UTV,using a coupling device 28 such as a ball joint, or heim joint, or thelike.

FIG. 1 is a front section view of a UTV portal axle system 10, mountedto a vehicle, in accordance with an embodiment. As shown in FIG. 1, tire58 is supported on the ground 54, and mounted to wheel hub 56, which iscoupled to the UTV portal axle system 10. King pin axis 48 is the linethat passes through the centers of coupling devices 28 of the upper andlower brackets, 20 and 24, respectively. Scrub radius 52, is thedistance of separation between king pin axis 48 and the center 50 of thecontact patch of the tire 58 where the tire 58 meets the ground 54. Theinclination angle 64 of the king pin axis 48 is the angle between theking pin axis 48 and center line 66, wherein the center line 66 is theline passing vertically through the center 50 of the contact patch ofthe tire 58 where the tire 58 meets the ground 54.

In accordance with the present invention, embodiments of a UTV portalaxle system 10 comprise an input drive gear 34 and an output drive gear36 housed within the housing 14 of the spindle 12. In some embodiments,the spindle 12 also comprises at least one idler gear 38 housed withinthe housing 14. Each of the input drive gear 34, the output drive gear36, and the at least one idler gear 38 may be a spur gear, a helicalgear, or the like.

The input drive gear 34 may be rotationally coupled within the housing14, the input drive gear 34 being configured for coupling to a driveaxle 40 of the UTV. For example, the input drive gear 34 may have asplined aperture therethrough for receiving a splined end of the driveaxle 40. The drive axle 40 may extend through a first aperture 60 in thehousing to engage the input drive gear 34 within the housing 14 suchthat the longitudinal axes of the drive axle 40 and the input drive gear34 are colinear and the input drive gear 34 rotates in response torotation of the drive axle 40. The input drive gear 34 may be mounted,for example, by a bearing, such as a ball bearing or pin bearing, or thelike, to a pin that protrudes from a wall of the housing 14.Alternatively, the pin may protrude from a cover plate 44 that isintegrated into a wall of the housing 14. In some embodiments, thebearing may be coupled within a bearing aperture in a wall of thehousing 14. The means by which the drive axle 40 is coupled to the inputdrive gear 34, and the means by which the input drive gear 34 is coupledto the housing 14, as described herein, are not intended to be limiting.The drive axle 40 may be coupled to the input drive gear 34, and theinput drive gear 34 may be coupled to the housing 14, by any means thatis consistent with the intended functionality of a UTV portal axlesystem 10 in accordance with the present invention.

The output drive gear 36 may be rotationally coupled within the housing14, the output drive gear 36 being configured for coupling to a wheelhub shaft 42 of the UTV. For example, the output drive gear 36 may havea splined aperture therethrough for receiving a splined end of the hubshaft 42. The hub shaft 42 may extend through a second aperture 62 inthe housing 14 to engage the output drive gear 36 within the housing 14such that longitudinal axes of the hub shaft 42 and the output drivegear 36 are colinear and the hub shaft 42 rotates in response torotation of the output drive gear 36. The output drive gear 36 may bemounted, for example, by a bearing, such as a ball bearing or pinbearing, or the like, to a pin that protrudes from a wall of the housing14. Alternatively, the pin may protrude from a cover plate 44 that isintegrated into a wall of the housing 14. In some embodiments, thebearing may be coupled within a bearing aperture in a wall of thehousing. The means by which the hub shaft 42 is coupled to the outputdrive gear 36, and the means by which the output drive gear 36 iscoupled to the housing 14, as described herein, are not intended to belimiting. The hub shaft 42 may be coupled to the output drive gear 36,and the output drive gear 36 may be coupled to the housing 14, by anymeans that is consistent with the intended functionality of a UTV portalaxle system 10 in accordance with the present invention.

In embodiments, the output drive gear 36 may be disposed, within thehousing 14, a predetermined spaced distance 46 below, and substantiallycoplanar with, the input drive gear 34, such that the output drive gear36 does not engage the input drive gear 34. The distance 46 between thecenters of the input and output drive gears 34 and 36 corresponds to theamount of additional lift, or ground clearance, provided to the UTV bythe UTV portal axle system 10. For example, the distance 46 between thecenters of the input and output drive gears 34 and 36 may be 4 inches or6 inches or 8 inches, corresponding to a 4-inch, 6-inch, or 8-inch lift,respectively. However, the distance 46 between the centers of the inputand output drive gears 34 and 36 is not intended to be limited to 4inches or 6 inches or 8 inches. The distance 46 between centers of theinput and output drive gears 34 and 36 may be any distance 46,corresponding to the amount of desired lift, provided the distance 46 isconsistent with the intended functionality of a UTV portal axle system10 of the present invention.

In some embodiments, torque may be transferred from the input drive gear34 to the output drive gear 36 by means of at least one idler gear 38rotationally coupled within the housing 14, wherein the at least oneidler gear 38 is disposed substantially coplanar with the input andoutput drive gears 34 and 36. For example, some embodiments may comprisea single idler gear 38 and other embodiments may comprise two idlergears 38. In embodiments that comprise at least one idler gear 38, theat least one idler gear 38 meshes with both the input and output drivegears 34 and 36 such that rotation of the input drive gear 34, inresponse to rotation of the drive axle 40, rotates the at least oneidler gear 38, which, in turn, rotates the output drive gear 36.Rotation of the input drive gear 34 in a first direction rotates the atleast one idler gear 38 in a second direction and rotation of the atleast one idler gear 38 in the second direction rotates the output idler36 gear in the first direction.

Some embodiments may not comprise an idler gear 38. In such embodiments,the input drive gear 34 may engage the output drive gear 36 directly.However, in such embodiments, the direction of rotation of the outputdrive gear 36 is opposite the direction of rotation of the input drivegear 34. It is preferable that the direction of rotation of the outputdrive gear 36 is the same as the direction of rotation of the inputdrive gear 34. In some embodiments, the input and output drive gears 34and 36 may be sprockets or pulleys that are coupled together by a chainor a belt, respectively, or the like, such that the direction ofrotation of the output drive gear 36 is the same as the direction ofrotation of the input drive gear 34.

As discussed briefly above, one problem with conventional after-marketUTV portal axle systems is that they comprise a gear box coupled to aspindle of the UTV. The king pin axis is defined as the line passingthrough the centers of the upper bracket and the lower bracket of thespindle, and the scrub radius is the distance in front view between theking pin axis and the center 7 of the contact patch of a tire mounted tothe wheel hub. Having a scrub radius of substantially one (1) inch orless allows a driver of the UTV to maintain proper control of thevehicle while steering the vehicle, with a comfortable amount offeedback in the steering wheel, whether at low speeds or high speeds,without significant shock loads being transferred to the steering wheelfrom the wheels encountering rough and uneven terrain. Due to thethickness of the conventional gear box, the scrub radius is increased byan amount equal to the thickness of the gear box when the original stockking pin axis inclination angle is maintained. For example, the scrubradius may be increased by 2 or 3 inches or more in comparison with theoriginal stock scrub radius. This results in substantial steeringfeedback problems, particularly when the UTV is driven over roughterrain and/or at high speeds, such as at speeds over 30 mph.

In accordance with the present invention, the output drive gear 36 is arecessed gear, as shown in FIGS. 1 and 2. The recess 90 of the outputdrive gear 36 allows for the lower bracket 24 to be disposed within therecess 90, thereby maintaining the scrub radius 52 to not more than oneinch while the original stock king pin axis inclination angle 64 ismaintained. In this way, the geometry of the original stock suspensionsystem is substantially maintained, allowing for safe use of the UTV onrough terrain and/or at high speeds, such as at speeds over 30 mph,without the steering feedback problems associated with conventionalafter-market UTV portal axle systems.

It is preferable, particularly for steered drive wheels, for the lowerbracket 24 to be located in line with the longitudinal axis of the wheelhub shaft 42 to avoid further problems associated with steering feedbackcaused by the lower bracket 24 being located in a position that is notso aligned.

In embodiments, the housing 14 may contain lubricating fluid forlubricating the gears within the housing 14. The housing 14 may comprisea fill port for filling the housing 14 with lubricating fluid and adrain port for draining the lubricating fluid from the housing 14.

In some embodiments, any of the input drive gear 34, the output drivegear 36, and the at least one idler gear 38, may be removable andreplaceable with a gear of a different diameter. Thus, the gear ratiobetween input to and output from the housing 14 may be increased ordecreased. A lower gear ratio may be suitable for use of the UTV at lowspeeds, and a higher gear ratio may be suitable for use of the UTV athigh speeds.

For example, a first set of gears may comprise the input drive gear 34,the output drive gear 36, and, in embodiments with at least one idlergear 38, the at least one idler gear 38. In embodiments with at leastone cover plate 44, the at least one cover plate 44 may be removed,allowing the first set of gears to be removed, and a second set of gearsinstalled. Because at least one of the input drive gear 34, the outputdrive gear 36, or the at least one idler gear 38 of the second set ofgears has a different diameter than that of the first set of gears, thecenters of the gears are necessarily located in a different position, sothat the gears of the second configuration will mesh. For this reason,at least one second cover plate 44, having a pin configurationcorresponding to the configuration of the second set of gears is thenattached to the housing 14 in place of the at least one cover plate 44.Thus, a first set of gears may have a low gear ratio for use on the UTVdriven at low speeds, and a second set of gears may have a high gearratio for use on the UTV driven at high speeds.

A method 100 of changing the gear ratio of a UTV portal axle system isalso disclosed. The method 100 comprises: removing the at least onefirst cover plate [Step 102]; removing at least one gear of a first setof gears including the input drive gear, the output drive gear, and theat least one idler gear [Step 104]; replacing the at least one removedgear with a second gear of a different size to form a second set ofgears with a gear ratio different from that of the first set of gears[Step 106]; and replacing the at least one first cover plate with asecond cover plate having the at least one mounting pin coupled theretoin a different location from that of the first cover plate, such thatthe second set of gears meshes in accordance with the functionality ofthe UTV portal axle system . . . [Step 108].

The components defining any UTV portal axle system 10 may be formed ofany of many different types of materials or combinations thereof thatcan readily be formed into shaped objects provided that the componentsselected are consistent with the intended operation of a UTV portal axlesystem 10. For example, the components may be formed of: rubbers(synthetic and/or natural) and/or other like materials; glasses (such asfiberglass) carbon-fiber, aramid-fiber, any combination thereof, and/orother like materials; polymers such as thermoplastics (such as ABS,Fluoropolymers, Polyacetal, Polyamide; Polycarbonate, Polyethylene,Polysulfone, and/or the like), thermosets (such as Epoxy, PhenolicResin, Polyimide, Polyurethane, Silicone, and/or the like), anycombination thereof, and/or other like materials; composites and/orother like materials; metals, such as zinc, magnesium, titanium, copper,iron, steel, carbon steel, alloy steel, tool steel, stainless steel,aluminum, any combination thereof, and/or other like materials; alloys,such as aluminum alloy, titanium alloy, magnesium alloy, copper alloy,any combination thereof, and/or other like materials; any other suitablematerial; and/or any combination thereof.

Furthermore, the components defining any UTV portal axle system 10 maybe purchased pre-manufactured or manufactured separately and thenassembled together. However, any or all of the components may bemanufactured simultaneously and integrally joined with one another.Manufacture of these components separately or simultaneously may involveextrusion, pultrusion, vacuum forming, injection molding, blow molding,resin transfer molding, casting, forging, cold rolling, milling,drilling, reaming, turning, grinding, stamping, cutting, bending,welding, soldering, hardening, riveting, punching, plating, and/or thelike. If any of the components are manufactured separately, they maythen be coupled with one another in any manner, such as with adhesive, aweld, a fastener (e.g. a bolt, a nut, a screw, a nail, a rivet, a pin,and/or the like), wiring, sewing, any combination thereof, and/or thelike for example, depending on, among other considerations, theparticular material forming the components. Other possible steps mightinclude sand blasting, polishing, powder coating, zinc plating,anodizing, hard anodizing, and/or painting the components for example.

The embodiments and examples set forth herein were presented in order tobest explain the present invention and its practical application and tothereby enable those of ordinary skill in the art to make and use theinvention. However, those of ordinary skill in the art will recognizethat the foregoing description and examples have been presented for thepurposes of illustration and example only. The description as set forthis not intended to be exhaustive or to limit the invention to theprecise form disclosed. Many modifications and variations are possiblein light of the teachings above without departing from the spirit andscope of the forthcoming claims.

1. A UTV portal axle system, comprising: a spindle, comprising: ahousing; an upper bracket configured for operational coupling to anupper control arm of a UTV; and a lower bracket configured foroperational coupling to a lower control arm of the UTV; an input drivegear rotationally coupled within the housing, the input drive gear beingconfigured for coupling to a drive axle of the UTV, the drive axleextending through a first aperture in the housing, wherein the inputdrive gear rotates in response to rotation of the drive axle; a recessedoutput drive gear rotationally coupled within the housing apredetermined distance below the input drive gear corresponding to theadditional ground clearance desired to be provided to the UTV by the UTVportal axle system, the output drive gear being configured for couplingto a shaft of a drive hub of the UTV, the shaft extending through asecond aperture in the housing, wherein the drive hub rotates inresponse to rotation of the output drive gear, wherein the output drivegear is separated from the input drive gear, the lower bracket beingdisposed within the recess of the output drive gear, wherein the kingpin axis is aligned such that the scrub radius of the wheel of the UTVis not more than one inch; and at least one idler gear rotationallycoupled within the housing, wherein the at least one idler gear mesheswith both the input and output drive gears such that rotation of theinput drive gear, in response to rotation of the drive axle, rotates theat least one idler gear, which, in turn, rotates the output drive gear.2. The UTV portal axle system of claim 1, wherein the king pin axisangle is substantially the same as the original stock king pin axisangle of the UTV.
 3. The UTV portal axle system of claim 2 comprising:two idler gears.
 4. The UTV portal axle system of claim 1, wherein thehousing comprises: a first cover plate having at least one mounting pincoupled thereto for rotational coupling to one of the input drive gearand the at least one idler gear within the housing, wherein the gearratio of the UTV portal axle system may be changed by: removing the atleast one first cover plate; removing at least one gear of a first setof gears including the input drive gear, the output drive gear, and theat least one idler gear; replacing the at least one removed gear with asecond gear of a different size to form a second set of gears with agear ratio different from that of the first set of gears; and replacingthe at least one first cover plate with a second cover plate having theat least one mounting pin coupled thereto in a different location fromthat of the first cover plate, such that the second set of gears meshesin accordance with the functionality of the UTV portal axle system asdescribed in claim
 1. 5. The UTV portal axle system of claim 4, whereinthe king pin axis angle is substantially the same as the original stockking pin axis angle of the UTV.
 6. The UTV portal axle system of claim 5comprising: two idler gears.
 7. A UTV portal axle system, comprising: aUTV, comprising: a spindle operationally coupled to a drive wheel of theUTV, the spindle comprising: a housing; an upper bracket configured foroperational coupling to an upper control arm of the UTV; and a lowerbracket configured for operational coupling to a lower control arm ofthe UTV; an input drive gear rotationally coupled within the housing,the input drive gear being configured for coupling to a drive axle ofthe UTV, the drive axle extending through a first aperture in thehousing, wherein the input drive gear rotates in response to rotation ofthe drive axle; a recessed output drive gear rotationally coupled withinthe housing a predetermined distance below the input drive gearcorresponding to the additional ground clearance desired to be providedto the UTV by the UTV portal axle system, the output drive gear beingconfigured for coupling to a shaft of a drive hub of the UTV, the shaftextending through a second aperture in the housing, wherein the drivehub rotates in response to rotation of the output drive gear, whereinthe output drive gear is separated from the input drive gear, the lowerbracket being disposed within the recess of the output drive gear,wherein the king pin axis is aligned such that the scrub radius of thewheel of the UTV is not more than one inch; and at least one idler gearrotationally coupled within the housing, wherein the at least one idlergear meshes with both the input and output drive gears such thatrotation of the input drive gear, in response to rotation of the driveaxle, rotates the at least one idler gear, which, in turn, rotates theoutput drive gear.
 8. The UTV portal axle system of claim 7, wherein theking pin axis angle is substantially the same as the original stock kingpin axis angle of the UTV.
 9. The UTV portal axle system of claim 8comprising: two idler gears.
 10. The UTV portal axle system of claim 7,wherein the housing comprises: a first cover plate having at least onemounting pin coupled thereto for rotational coupling to one of the inputdrive gear and the at least one idler gear within the housing, whereinthe gear ratio of the UTV portal axle system may be changed by: removingthe first cover plate; removing at least one gear of a first set ofgears including the input drive gear, the output drive gear, and the atleast one idler gear; replacing the at least one removed gear with asecond gear of a different size to form a second set of gears with agear ratio different from that of the first set of gears; and replacingthe first cover plate with a second cover plate having the at least onemounting pin coupled thereto in a different location from that of thefirst cover plate, such that the second set of gears meshes inaccordance with the functionality of the UTV portal axle system asdescribed in claim
 1. 11. The UTV portal axle system of claim 10,wherein the king pin axis angle is substantially the same as theoriginal stock king pin axis angle of the UTV.
 12. The UTV portal axlesystem of claim 11 comprising: two idler gears.
 13. A method of changingthe gear ratio of a UTV portal axle system comprising: removing the atleast one first cover plate; removing at least one gear of a first setof gears including the input drive gear, the output drive gear, and theat least one idler gear; replacing the at least one removed gear with asecond gear of a different size to form a second set of gears with agear ratio different from that of the first set of gears; and replacingthe at least one first cover plate with a second cover plate having theat least one mounting pin coupled thereto in a different location fromthat of the at least one first cover plate, such that the second set ofgears meshes in accordance with the functionality of the UTV portal axlesystem as described in claim 1.